Systems and methods for wirelessly communicating within electric motor systems

ABSTRACT

An electric motor communication system for use with a fluid moving system and using at least one wireless sensor network is provided. The electric motor communication system includes an electric motor that includes a motor management device configured to transmit and receive input signals via the wireless sensor network, and a processing device coupled to said motor management device and configured to control said electric motor based at least in part on input signals received at said motor management device. The electric motor communication system also includes at least one external device configured to collect data and to transmit said input signals, via the wireless sensor network, to said electric motor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 15/703,356, filed Sep. 13, 2017, all of which isincorporated herein by reference.

BACKGROUND

The field of the disclosure relates generally to electric motor controlsystems, and more particularly, to wireless communications betweenelectric motors and other devices using a wireless sensor network.

At least some known motor control systems include power switches forgenerating a motor control signal for an electric motor. The motorcontrol systems may further include a wireless communication interfaceto facilitate remote control of the motor control system and thereby theelectric motor. Some motor control systems may include both the powerswitches and the wireless communication interface within one package,printed circuit board (PCB), or other enclosure.

At least some known electric motors are coupled to a power controlsystem by one or more wireless network (e.g., Wi-Fi™). Electric motorsmay also be connected to other external devices. These wireless networksrequire additional hardware that enables the transmission of wirelesssignals between the electric motors and other devices. Furthermore, thetransmission of the wireless signals is subject to the additionalhardware functioning properly and a wireless network provider deliveringthe wireless signals.

BRIEF DESCRIPTION

In one aspect, an electric motor communication system for use with afluid moving system and using at least one wireless sensor network isprovided. The electric motor communication system includes an electricmotor that includes a motor management device configured to transmit andreceive input signals via the wireless sensor network, and a processingdevice coupled to said motor management device and configured to controlsaid electric motor based at least in part on input signals received atsaid motor management device. The electric motor communication systemalso includes at least one external device configured to collect dataand to transmit said input signals, via the wireless sensor network, tosaid electric motor.

In another aspect, an electric motor for use in a fluid-moving system incommunication with a wireless sensor network is provided. The electricmotor includes a motor management device configured to transmit andreceive input signals, via the wireless sensor network, to and from atleast one external device, and a processing device coupled to said motormanagement device and configured to control said electric motor based atleast in part on input signals received at said motor management device.

In yet another aspect, a method of operating an electric motor in afluid-moving system and performed using a wireless sensor network isprovided. The method includes communicatively coupling the electricmotor to at least one external device, via the wireless sensor network,the electric motor including a motor management device and a processingdevice coupled to the motor management device. The method also includesreceiving, at the motor management device, input signals from the atleast one external device, and controlling, using the processing device,the electric motor based at least in part on the received input signals.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of an exemplary electric motor.

FIG. 2 is a block diagram of an exemplary motor control assembly forcontrolling operation of the electric motor shown in FIG. 1 , includinga motor management device.

FIG. 3 is a perspective view of the motor control assembly shown inFIGS. 1 and 2 , including the motor management device.

FIG. 4 is a schematic diagram of exemplary sensors and a data managementsystem of the motor controller shown in FIG. 2 .

FIG. 5 is a schematic diagram of a motor management system of the motorcontroller shown in FIG. 2 .

FIG. 6A is a schematic diagram of an exemplary motor communicationsystem that may be used with the electric motor shown in FIG. 1 .

FIG. 6B is a schematic diagram of an alternative motor communicationsystem that may be used with the electric motor shown in FIG. 1 .

FIG. 6C is a schematic diagram of an alternative motor communicationsystem that may be used with the electric motor shown in FIG. 1 ,

FIG. 6D is a schematic diagram of an alternative motor communicationsystem that may be used with two electric motors similar to the electricmotor shown in FIG. 1 .

FIG. 7 is a block diagram of an exemplary computing device that may beused with the motor control assembly shown in FIG. 2 .

DETAILED DESCRIPTION

The methods and systems described herein facilitate efficient andeconomical operation of electric motor systems. As described herein, anelectric motor communication system includes at least one electric motorincluding a motor management device and a processing device. Using themotor management device, the electric motor interfaces with a pluralityof external devices without requiring physical connections and awireless sensor network (WSN) between the external devices and theelectric motor. The electric motor is configured to operate withinitself. That is, the electric motor is able to control its operationswithout an external controller.

Technical effects of the methods and systems described herein include atleast one of: (a) communicatively coupling an electric motor to at leastone external device; (b) receiving and transmitting input signals fromthe at least one external device; (c) controlling the electric motorbased at least in part on the received input signals; (d) controllingthe electric within itself without the need of an external controller;and (e) troubleshooting the electric motor based at least in part on thetransmitted signals.

FIG. 1 is an exploded view of an exemplary electric motor 10. Electricmotor 10 includes control system 11, a stationary assembly 12 includinga stator or core 14, and a rotatable assembly 16 including a rotor 18and a shaft 20. In the exemplary embodiment, electric motor 10 isutilized as a fan and/or blower motor in a fluid (e.g., water, air,etc.) moving system. For example, electric motor 10 may be utilized in aclean room filtering system, a fan filter unit, a variable air volumesystem, a refrigeration system, a furnace system, an air conditioningsystem, and/or a residential or commercial heating, ventilation, and airconditioning (HVAC) system. Alternatively, electric motor 10 may beimplemented in any application that enables electric motor 10 tofunction as described herein. Electric motor 10 may also be used todrive mechanical components other than a fan and/or blower, includingmixers, compressors, gears, conveyors, and/or treadmills. In theexemplary embodiment, control system 11 is integrated with electricmotor 10. Alternatively, electric motor 10 may be external to and/orseparate from control system 11.

Rotor 18 is mounted on and keyed to shaft 20 journaled for rotation inconventional bearings 22. Bearings 22 are mounted in bearing supports 24integral with a first end member 26 and a second end member 28. Endmembers 26 and 28 have inner facing sides 30 and 32 between whichstationary assembly 12 and rotatable assembly 16 are located. Each endmember 26 and 28 has an outer side 34 and 36 opposite its inner side 30and 32. Additionally, second end member 28 has an aperture 38 for shaft20 to extend through outer side 36.

Rotor 18 comprises a ferromagnetic core 40 and is rotatable withinstator 14. Segments 42 of permanent magnet material, each providing arelatively constant flux field, are secured, for example, by adhesivebonding to rotor core 40. Segments 42 are magnetized to be polarizedradially in relation to rotor core 40 with adjacent segments 42 beingalternately polarized as indicated. While magnets on rotor 18 areillustrated for purposes of disclosure, it is contemplated that otherrotors having different constructions and other magnets different inboth number, construction and flux fields may be utilized with suchother rotors within the scope of the invention.

Stationary assembly 12 comprises a plurality of winding stages 44adapted to be electrically energized to generate an electromagneticfield. Stages 44 are coils of wire wound around teeth 46 of laminatedstator core 14. Winding terminal leads 48 are brought out through anaperture 50 in first end member 26 terminating in a motor connector 52.While stationary assembly 12 is illustrated for purposes of disclosure,it is contemplated that other stationary assemblies of various otherconstructions having different shapes and with different number of teethmay be utilized within the scope of the invention.

Electric motor 10 further includes an electronics enclosure 54 thatmounts on the rear portion of electric motor 10 to house control system11. Electronics enclosure 54 includes a bottom wall 56 and asubstantially annular side wall 57. Electronics enclosure 54 defines aninternal chamber (not shown) in which control system 11 is positioned.Electronics enclosure 54 and control system 11 may sometimes be referredto collectively as a motor control assembly 55. Control system 11includes a plurality of electronic components 58 and a connector 59mounted within electronics enclosure 54. Control system 11 is connectedto winding stages 44 by interconnecting motor connector 52. Controlsystem 11 applies a voltage to one or more of winding stages 44 at atime for commutating winding stages 44 in a preselected sequence torotate rotatable assembly 16 about an axis of rotation. In analternative embodiment, control system 11 is remotely positioned fromand communicatively coupled to electric motor 10. In another alternativeembodiment, control system 11 is a central control system for more thanone electric motor (e.g., in an HVAC system), and is communicativelycoupled to electric motor 10.

A casing 72 is positioned between first end member 26 and second endmember 28 to facilitate enclosing and protecting stationary assembly 12and rotatable assembly 16.

FIG. 2 is a block diagram of an exemplary motor control assembly 55 forcontrolling operation of electric motor 10 including a motor managementdevice (not shown) for receiving and transmitting input signals. FIG. 3is a perspective view of motor control assembly 55 including the motormanagement device. FIG. 4 is an exploded perspective view of motorcontrol assembly 55. In the exemplary embodiment, motor control assembly55 includes electronics enclosure 54 and internal chamber 60, whichhouses control system 11 (shown in FIG. 1 ). Control system 11 includesa power supply module 200 and motor management module 201 that isphysically separate from, but in electrical connection with power supplymodule 200.

Power supply module 200 includes a plurality of electrical components202, an output connector 203 mounted on a component board, such as aprinted circuit board (PCB) 204, and an input connector 205. Powersupply module 200 integrates large through-hole electrical components202 and power connectors of control system 11. In the exemplaryembodiment, PCB 204 is coupled to an interior surface of bottom wall 56of electronics enclosure 54.

In the exemplary embodiment, input connector 205 includes power inputline connectors 206 for coupling to a power source 207. Input connector205 interfaces with and receives input power from power source 207 viaan opening inside wall 57 of electronics enclosure 54.

Electrical components 202 of power supply module 200 are configured toconvert input voltage received from power source 207 to a desired levelof direct current (DC) voltage. Using output connector 203, power supplymodule 200 outputs the converted DC voltage to motor management module201. Output connector 203 includes two high-voltage wires 208 forproviding the converted DC voltage to motor management module 201.

Motor management module 201 includes an input/output connector 211 andelectrical components 202. Motor management module 201 housesmoisture-sensitive electrical components 202 of control system 11 withinan encapsulated, heat-sharing package 212 that provides protection fromdamage and/or failure due to moisture entering electronics enclosure 54,as described in more detail herein.

Heat-sharing package 212 includes an insulated metal substrate 213coupled to a metal heatsink 214 formed in side wall 57 of electronicsenclosure 54. For example, heat-sharing package 212 may include aninsulated metal substrate (IMS) or a thick printed copper (TPC) basedpackaging to integrate high power semiconductor devices and allmoisture-sensitive components such as integrated circuits and surfacemount resistors. Heat generated by electrical losses of thesemiconductor devices causes the elements mounted on the heat sharingpackage 212 to operate at relatively higher temperatures.

Input/output connector 211 is coupled to high-voltage wires 208 forreceiving the converted DC voltage from power supply module 200. Motormanagement module 201 converts the DC voltage to a three-phasealternating current (AC) voltage for driving electric motor 10 based oninstructions received from external devices (not shown). Input/outputconnector 211 outputs the three-phase AC voltage to winding stages 44(shown in FIG. 1 ) of electric motor 10 via output power wires 215.

In the exemplary embodiment, motor management device 216 iscommunicatively coupled to the external devices as well as otherelectric motors 10. More specifically, in the exemplary embodiment motormanagement device 216 is communicatively coupled to the external devicesand other electric motors 10 using a WSN that transmits the inputsignals. The input signals may be sensor input signals. In someembodiments, the input signals are transmitted by the external devicesand received by one or more electric motors 10. In other embodiments,the input signals are transmitted from one or more electric motors 10and received by the external devices. In yet other embodiments, theinput signals are transmitted from and received by one or more electricmotors 10. In some embodiments, a wired communication connection maytransmit the input signals. In the example embodiment, the input signalsinclude Bluetooth® and Bluetooth® Low Energy (BLE®) signals. Inalternative embodiments, the input signals may include, but are notlimited to, near field communications (NFC), infrared, Wi-Fi™, and/orany other known types of input signals.

In some embodiments, motor management device 216 is controlled by auser, such as an original equipment manufacturer (OEM), and enablescontrol of motor operation by transmitting control signals to theexternal devices and other electric motors 10.

FIG. 5 is a block diagram of an exemplary motor management module 201.In the exemplary embodiment, motor management module 201 includesinput/output connector 211 for receiving the DC voltage from powersupply module 200 (shown in FIG. 2 ), power semiconductor switches 500for switching the DC power to the motor phases as AC power, amicrocontroller 502 for implementing an algorithm to control one or moregate drivers 504 to operate power semiconductor switches 500, a lowvoltage power supply 506 and associated internal circuitry for providinglow voltage power to microcontroller 502 from a higher voltage that isapplied to entire motor management module 201, and input/outputconnector 211 for coupling to motor winding stages. In the exemplaryembodiment, low voltage power supply 506 is a DC-DC converter thatsupplies low voltage sources to microcontroller 502 and to a wirelesscommunications module 508, such as motor management device 216 (shown inFIG. 3 ).

In the exemplary embodiment, motor management module 201 also includes aplurality of sensors 510 for providing data to microcontroller 502.Sensors 510 are configured to measure various operating parametersassociated with the operation of electric motor 10, including voltagemeasurements, current measurements, temperature measurements, vibrationmeasurements, and/or any other known measurements associated withoperating an electric motor or the operating environment. Sensors 510are contained within heat-sharing package 212 (shown in FIG. 3 ) and donot require penetration out of sharing package 212, which would createpotential for moisture penetration.

In the exemplary embodiment, motor management module 201 includeswireless communication module 508 for communicating with externaldevices and other electric motors 10 to receive a motor control commandsignal, which is used by microcontroller 502 to switch powersemiconductor switches 500 to drive electric motor 10 at an appropriatelevel. Wireless communication module 508 communicates with one or moreremote devices, such as the external devices and other electric motors10. In the exemplary embodiment, wireless communication module 508converts a received input signal into a control signal thatmicrocontroller 502 utilizes to control operation of electric motor 10.By using wireless communication module 508 to communicate with theexternal devices and other electric motors 10, hardwired communicationconnectors are eliminated. Such hardwired connectors are a common entrypoint for moisture, so their removal makes electric motor 10 moreresistant to moisture. In addition, the number of hardwires is reducedfacilitating maintenance of electric motor 10.

In some embodiments, casing 72 and/or electronics enclosure 54 (bothshown in FIG. 1 ) are manufactured using metal, which may interfere withinput signals being transmitted to microcontroller 502. As such, motormanagement module 201 may be positioned adjacent to an opening 512defined in casing 72 or electronics enclosure 54. Motor managementmodule 201 includes an antenna 514 within the over-molded portion ofheat-sharing package 212 such that an input signal entering electronicsenclosure 54 via opening 512 penetrates sharing package 212 and isreceived by antenna 514. Antenna 514 enables wireless communicationbetween a user of electric motor 10 (i.e., a manufacturer of electricmotor 10, an HVAC system manufacturer using electric motor 10, atechnician of electric motor 10, and/or a customer owning electric motor10) with microcontroller 502 to define, change, or override theoperating parameters stored in a microcontroller memory device.Positioning antenna 514 adjacent to opening 512 enables input signals tobe received by antenna 514 and transmitted to microcontroller 502. Insome embodiments, antenna 514 is a three-dimensional (3D) antenna or aceramic antenna. In other embodiments, other suitable types of antennasmay be used.

In the exemplary embodiment, microcontroller 502 includes at least onememory device 516 and a processor 518 that is communicatively coupled tomemory device 516 for executing instructions. In some embodiments,executable instructions are stored in memory device 516. In theexemplary embodiment, microcontroller 502 performs one or moreoperations described herein by programming processor 518. For example,processor 518 may be programmed by encoding an operation as one or moreexecutable instructions and by providing the executable instructions inmemory device 516.

Processor 518 may include one or more processing units (e.g., in amulti-core configuration). Further, processor 518 may be implementedusing one or more heterogeneous processor systems in which a mainprocessor is present with secondary processors on a single chip. Asanother illustrative example, processor 518 may be a symmetricmulti-processor system containing multiple processors of the same type.Further, processor 518 may be implemented using any suitableprogrammable circuit including one or more systems and microcontrollers,microprocessors, reduced instruction set circuits (RISC), applicationspecific integrated circuits (ASIC), programmable logic circuits, fieldprogrammable gate arrays (FPGA), and any other circuit capable ofexecuting the functions described herein. In the exemplary embodiment,processor 518 controls operation of microcontroller 502.

In the exemplary embodiment, memory device 516 is one or more devicesthat enable information such as executable instructions and/or otherdata to be stored and retrieved. Memory device 516 may include one ormore computer readable media, such as, without limitation, an NFCelectrically erasable programmable read-only memory (EEPROM), a standardEEPROM, dynamic random access memory (DRAM), static random access memory(SRAM), a solid state disk, and/or a hard disk. Memory device 516 may beconfigured to store, without limitation, application source code,application object code, source code portions of interest, object codeportions of interest, configuration data, execution events, and/or anyother type of data. In the exemplary embodiment, memory device 516includes firmware and/or initial motor configuration data formicrocontroller 502. Moreover, in the exemplary embodiment, memorydevice 516 stores diagnostic data associated with operation of electricmotor 10, for transmission to one or more external devices upon request.Diagnostic data includes, but is not limited to including, time powered,time run, time run above 80% demand, time in speed cutback region, timein temperature cutback region, good starts, failed starts, resets,stalls, number of bad serial packets received, watchdog shutdown events,time run in certain demand ranges, thermal shock events, power moduletemperature, bus voltage, open-phase events, UL lockouts, reverse startattempts, shaft watts, and torque.

FIG. 6A is a schematic diagram of an exemplary electric motorcommunication system 600. Electric motor communication system 600includes at least one electric motor 602, similar to electric motor 10(shown in FIG. 1 ), and a plurality of external devices 604. Asdescribed in detail herein, electric motor 602 is communicativelycoupled to one or more external devices 604 and other electric motors602 such that electric motor 602 is capable of bi-directional wirelesscommunication with one or more external devices 604 and/or otherelectric motors 602. More specifically, any electric motor 602 within aWSN is capable of wirelessly communicating with external devices 604and/or other electric motors 602.

In the exemplary embodiment, electric motor 602 is utilized as a fanand/or blower motor in a fluid (e.g., water, air, etc.) moving system.For example, electric motor 602 may be utilized in a clean roomfiltering system, a fan filter unit, a variable air volume system, arefrigeration system, a furnace system, an air conditioning system,and/or a residential or commercial heating, ventilation, and airconditioning (HVAC) system. Alternatively, electric motor 602 may beimplemented in any application that enables electric motor communicationsystem 600 to function as described herein. Electric motor 602 may alsobe used to drive mechanical components other than a fan and/or blower,including mixers, compressors, gears, conveyors, and/or treadmills.

Electric motor 602 includes a processor 606 that controls operation ofelectric motor 602 and facilitates wireless communication betweenelectric motor 602, external devices 604, and other electric motors 602,as described in detail below. In the exemplary embodiment, processor 606is communicatively coupled to a motor management device 608, similar tomotor management device 216 (shown in FIG. 3 ), configured to transmitinput signals to one or more external devices 604 and/or other electricmotors 602. Motor management device 608 is also configured to receiveinput signals from one or more external devices 604 and/or otherelectric motors 602. Similarly, external devices 604 each include amotor management device 610 for transmitting and receiving input signalsto and from electric motor 602. In the exemplary embodiment, motormanagement devices 608 and 610 have antenna, similar to antenna 514(shown in FIG. 5 ). Alternatively, motor management devices 608 and/or610 are any device that enables electric motor communication system 600to function as described herein.

In the exemplary embodiment, electric motor 602 communicates withexternal devices 604 and other electric motors 602 via Wi-Fi™, Z-Wave®,Bluetooth®, and/or BLE® signals. Alternatively, electric motor 602communicates with external devices 604 and other electric motors 602using any communication medium and/or network that enables electricmotor communication system 600 to function as described herein.Exemplary networks include a mesh network, a cellular network, a generalpacket radio service (GPRS) network, an Enhanced Data Rates for GlobalEvolution (EDGE) network, a WiMAX network, a P1901 network, and/or aZIGBEE® network (e.g., ZigBee Smart Energy 1.0, ZigBee Smart Energy 2.0,ZIGBEE® is a registered trademark of ZigBee Alliance, Inc., of SanRamon, Calif.).

A plurality of different types of external devices 604 may communicatewirelessly with electric motor 602. In the exemplary embodiment,external devices 604 may include a wireless network adapter 612 (such asBLE®-Wi-Fi™ gateway and home automation hub like Amazon Echo®), adatabase server 614, a diagnostic tool 616, sensors 618, a repeater 620(e.g., a Bluetooth® repeater), and a computing device 622, eachdescribed in detail below. Alternatively, external devices 604 mayinclude any device capable of communicating with electric motor 602 viainput signals.

Wireless network adapter 612 uses wireless communication to interfacewith electric motor 602. In the exemplary embodiment, wireless networkadapter 612 is in communication with one or more routers that may becommunicatively coupled to the Internet through many interfacesincluding, but not limited to, at least one of a network, such as theInternet, a local area network (LAN), a wide area network (WAN), or anintegrated services digital network (ISDN), a dial-up-connection, adigital subscriber line (DSL), a cellular phone connection, and a cablemodem. By being in communication with wireless network adapter 612,electric motor 602 may have access to database server 614, diagnostictool 616, and any other device that electric motor 602 may require togain access to function as described herein.

Database server 614 uses wireless communication to receive and storedata related to operation of electric motor 602. In the exemplaryembodiment, database server 614 includes a memory device, similar tomemory device 516 (shown in FIG. 5 ). The data stored on database server614 may include, for example, diagnostic information for electric motor602, configuration data for electric motor 602, and/or measurements frommotor management device 608. Data may be transmitted to database server614 from electric motor 602 and, more specifically, motor managementdevice 608 periodically, continuously, and/or in response to user input.In the exemplary embodiment, database server 614 is communicativelycoupled to electric motor 602 via wireless adapter 612

Diagnostic tool 616 uses wireless communication to collect diagnosticinformation from electric motor 602. Diagnostic information may include,for example, input power consumption, operating speed, operating torquelevel, operating temperature, frequency of thermostat cycling, totalnumber of failures of electric motor 602 (fault event count), totallength of time that electric motor 602 has received power (total poweredtime), total length of time that electric motor 602 has operated at orabove a preset threshold (total run time), total length of time thatelectric motor 602 has operated at a speed that exceeds a preset rate ofspeed (total time in a cutback region), total time that electric motor602 has operated with a baseplate temperature over a preset thermallimit (total time over thermal limit), and/or total number of times thatelectric motor 602 has been started (total run cycles).

In the exemplary embodiment, the diagnostic information is stored in amemory device, similar to memory device 516, coupled to electric motor602. In one embodiment, motor management device 608 of electric motor602 periodically transmits diagnostic information stored to diagnostictool 616 and/or other external devices 604. In another embodiment, motormanagement device 608 transmits diagnostic information in response to arequest for diagnostic information sent by diagnostic tool 616 and/orother external devices 604.

In the exemplary embodiment, diagnostic tool 616 is a computing devicethat may include a presentation interface (not shown) that displays thediagnostic information to a user. The presentation interface may alsodisplay alerts and/or warnings to the user. For example, thepresentation interface may display a warning when an operatingconfiguration of electric motor 602 is malfunctioning, such as anoperating temperature of electric motor 602 is above a predeterminedthreshold or when a voltage abnormality is detected. In another example,if diagnostic information indicates unusual operation of electric motor602 indicative of malfunction of electric motor 602, the presentationinterface may display an alert that electric motor 602 needs to beinspected and/or troubleshot. In response to observing the alert and/orwarning, the user can take appropriate action.

Diagnostic tool 616 may further include a user input interface (notshown) that enables the user to request diagnostic information fromelectric motor 602 and/or control the information displayed ondiagnostic tool 616. In the exemplary embodiment, diagnostic tool 616 iscommunicatively coupled to at least one electric motor 602, via awireless network adapter 612. Accordingly, diagnostic tool 616 may beconfigured to wirelessly gather diagnostic information for a pluralityof electric motors 602 in a relatively short period of time. Forexample, in some embodiments, diagnostic information is gathered from aplurality of electric motors 602 simultaneously using a singlediagnostic tool 616. Diagnostic tool 616 is also configured totroubleshoot electric motor 602. For example, diagnostic tool 616 mayidentify a malfunction of electric motor 602 by using the collecteddiagnostic information. Once diagnostic tool 616 has identified themalfunction, diagnostics tool 616 generates a solution and transmitswirelessly the solution to the electric motor 602. The electric motor602 receives the solution and processor 606 executes the solution totroubleshoot the malfunction.

Sensors 618 uses input signals to interface with electric motor 602. Inthe exemplary embodiment, sensors 618 include a CO/NO_(x) sensor, a CO₂sensor, a vibration sensor, a temperature sensor, a pressure transducer,an indoor air quality (IAQ) sensor, and/or a sensor that measures one ormore operating parameters of electric motor 602. Alternatively, sensors618 may include any type of sensor that enables electric motorcommunication system 600 to function as described herein.

In the exemplary embodiment, one or more measurements taken by sensors618 are wirelessly transmitted to electric motor 602 via input signals.The operation of electric motor 602 is controlled based on the one ormore measurements. For example, if sensors 618 measure ambient airtemperature of electric motor 602 above a predetermined threshold, theprocessor may adjust one or more operating parameters (e.g., reduce theoperating speed) of electric motor 602 in response. In the exemplaryembodiment, sensors 618 include a plurality of user-selectable settings,or modes, related to operation of electric motor 602.

Repeater 620 uses a input signal transmitted by motor management device608 from one electric motor 602 and rebroadcasts the input signal toanother electric motor 602. In general, electric motor communicationsystem 600 includes at least one repeater 620 when the physical distancebetween electric motors 602 is greater than a range that the inputsignals may reach. That is, for example, if the distance between twoelectric motors 602 is 400 feet and the input signal range is 328 feet,at least one repeater 620 would be required for the input signals toreach each electric motor 602. Conversely, if the distance between twoelectric motors 602 is 300 feet and the input signal range is 328 feet,it is likely that a repeater 620 would not be required for the inputsignals to reach each electric motor 602.

FIG. 6B is a schematic diagram of an electric motor communication system650 implemented as part of an HVAC system. Electric motor communicationsystem 650 includes wireless network adapter 612, database server 614,diagnostic tool 616, a plurality of sensors 618, a repeater 620,computing device 622, three electric motors 652, 654, and 656, and awireless router 658. Electric motors 652, 654, and 656 are similar toelectric motor 602 (shown in FIG. 6A). In the exemplary embodiment,electric motors 652, 654, and 656 are communicatively coupled with eachother such that electric motors 652, 654, and 656 are capable ofbi-directional wireless communication with each other. Electric motor652 is communicatively coupled to sensors 618 such that electric motor652 is capable of bi-directional wireless communication with sensors618. Sensors 618 may include parameters related to low heat, high heat,cooling, dehumidify, and/or continuous fan modes.

In the exemplary embodiment, electric motor 652 is located inside an airhandler 662 and is in communication with wireless network adapter 612,sensors 618, and repeater 620. Wireless router 658 enables communicationbetween database server 614, diagnostic tool 616, and electric motors652, 654, and 656. Wireless router 658 also enables communicationbetween computing device 622 and electric motors 652, 654, and 656. Inat least some implementation, when computing device 622, wirelessadapter 612, and electric motors 652, 654, and 656 use similar wirelesstechnology, such as Bluetooth® Low Energy (BLE®), a direct communicationamong them may be achieved. Electric motors 654 and 656 are locatedinside an outdoor condenser 664 and are in communication with electricmotor 652 via repeater 620.

During operation, sensors 618 detect an ambient air temperature. In theexemplary embodiment, the detected air temperature is wirelesslytransmitted to electric motor 652 via input signals. The operation ofelectric motors 652, 654, and 656 is controlled based on the detectedair temperature. As a result, the three wireless communication basedelectric motors 652, 654, and 656 of the HVAC system operate in aself-driving mode (e.g., autonomous mode) without communicating towireless adapter 612. More specifically, in the exemplary embodiment,electric motor 652 operates as a primary electric motor and is referredto as a “master” electric motor, and motors 654 and 656 operate assecondary motors and are referred to as “slave” electric motors.Therefore, the HVAC system operates within a master-slave controlscheme. In an alternative embodiment, the operation of electric motors652, 654, and 656 is controlled based on a temperature set in computingdevice 622, database server 614, and/or diagnostic tool 616. Forexample, if electric motor 652 is blowing cool air, when electric motor652 receives a detected air temperature below a preset temperature, theprocessor of electric motor 652, such as processor 606 (shown in FIG.6A), may instruct electric motors 652, 654, and 656 to cease rotation(i.e., stop blowing cool air) and to transmit, via repeater 620, awireless signal to electric motors 654 and 656 instructing electricmotors 654 and 656 to cease rotation.

In some embodiments, sensors 618 are at least one of a CO/NO_(x) sensor,a CO₂ sensor, a vibration sensor, a temperature sensor, a pressuretransducer, an indoor air quality (IAQ) sensor, an air flow sensor, aradon sensor, and a sensor that measures at least one operatingparameter of electric motors 652.

FIG. 6C is a schematic diagram of an alternative electric motorcommunication system 670 implemented as part of an HVAC system. Electricmotor communication system 670 includes database server 614, diagnostictool 616, a plurality of sensors 618, a repeater 620, computing device622, three electric motors 652, 654, and 656, a wireless router 658, aninterface circuit 672, a system controller 674 insider indoor unit, anda wireless thermostat 676. A wire communication connection 678 is usedbetween thermostat 676 and system controller 674, and between systemcontroller 674 and interface circuit 672. Interface circuit 672 hassimilar wireless communication technology (e.g., Bluetooth® LowerEnergy) as electric motors 652, 654, and 656. Having similar wirelesstechnology enables wireless communication between interface circuit 674and electric motors 652, 654, and 656. In the exemplary embodiment,electric motor 652, interface circuit 672, and system controller 674 arelocated inside an air handler 662. Electric motor 652 is incommunication with interface circuit 672, sensors 618, and repeater 620.Electric motors 654 and 656 are located inside an outdoor condenser 664and are in communication with electric motor 652 via repeater 620.

During operation, wireless thermostat 660 detects ambient temperatureand transmits at least one input signal to system controller 674 viawired communication connection 678. Subsequently, system controller 674transmits the input signal to interface circuit 672 via wiredcommunication connection 678. Then, interface circuit 672 wirelesslytransmits the input signal to electric motor 652. Once electric motor652 receives the input signal, electric motor 652 transmits the input toelectric motors 654 and 656, via repeater 620, and activates the HVACsystem. Similar to electric motor communication system 650 illustratedin FIG. 6B, the operation of electric motors 652, 654, and 656 may becontrolled based on a detected air temperature from sensors 618.Electric motors 652, 654, and 656 may operate in a self-driving mode(e.g., autonomous mode) without communicating with computing device 622,thermostat 676, system controller 674, and/or interface circuit 672. Inthe exemplary embodiment, computing device 622 is in communication withwireless thermostat 676 via wireless router 658. Computing device 622may be in direct communication with electric motors 652, 654, and 656 ifcomputing device 622 and electric motors 652, 654, and 656 use similarwireless technology, such as Bluetooth® Lower Energy.

FIG. 6D is a schematic diagram of an alternative electric motorcommunication system 680 implemented as part of an HVAC system whichuses two motors (e.g. gas furnace). Electric motor communication system680 includes a wireless adapter 612, database server 614, diagnostictool 616, a plurality of sensors 618, computing device 622, a wirelessrouter 658, and two electric motors 652 and 668 located inside indoorunit 662. Electric motor 652 is in communication with wireless adapter612, sensors 618, and electric motor 668. In the exemplary embodiment,sensors 618 detect air temperature and wirelessly transmit the detectedair temperature, via an input signal, to electric motor 652. Then,electric motor 652 wirelessly transmits the input signal to electricmotor 658. In some embodiments, electric motors 652 and 668 may operatein a self-driving mode (e.g., autonomous mode) without communicatingwith computing device 622 and/or wireless adapter 612. In otherembodiments, computing device 622 may be in direct communication withelectric motors 652 and 668 if computing device 622 and electric motors652 and 668 use similar wireless technology, such as Bluetooth® LowerEnergy.

FIG. 7 is a block diagram of computing device 622 that may be incommunication with electric motor 10 (shown in FIG. 1 ). Computingdevice 622 may be any device capable of communicate with electric motor602, but is not limited to, a desktop computer, a laptop computer, apersonal digital assistant (PDA), a cellular phone, a smartphone, atablet, a phablet, or other wireless connectable equipment. Computingdevice 622 includes at least one memory device 710 and a processor 715that is coupled to memory device 710 for executing instructions. In someembodiments, executable instructions are stored in memory device 710. Inthe exemplary embodiment, computing device 622 performs one or moreoperations described herein by programming processor 715. For example,processor 715 may be programmed by encoding an operation as one or moreexecutable instructions and by providing the executable instructions inmemory device 710.

Processor 715 may include one or more processing units (e.g., in amulti-core configuration). Further, processor 715 may be implementedusing one or more heterogeneous processor systems in which a mainprocessor is present with secondary processors on a single chip. Asanother illustrative example, processor 715 may be a symmetricmulti-processor system containing multiple processors of the same type.Further, processor 715 may be implemented using any suitableprogrammable circuit including one or more systems and microcontrollers,microprocessors, reduced instruction set circuits (RISC), applicationspecific integrated circuits (ASIC), programmable logic circuits, fieldprogrammable gate arrays (FPGA), and any other circuit capable ofexecuting the functions described herein. In the exemplary embodiment,processor 715 controls operation of electric motor 10 via an applicationprogramming interface (API). In alternative embodiments, a predefinedconfiguration of electric motor 10 controls electric motor 10.

In the exemplary embodiment, memory device 710 is one or more devicesthat enable information such as executable instructions and/or otherdata to be stored and retrieved. Memory device 710 may include one ormore computer readable media, such as, without limitation, dynamicrandom access memory (DRAM), static random access memory (SRAM), a solidstate disk, and/or a hard disk. Memory device 710 may be configured tostore, without limitation, application source code, application objectcode, source code portions of interest, object code portions ofinterest, configuration data, execution events, and/or any other type ofdata. In the exemplary embodiment, memory device 710 includes firmwareand/or initial configuration data for electric motor 10.

In the exemplary embodiment, computing device 622 also includes apresentation interface 720 that is coupled to processor 715.Presentation interface 720 presents information, such as applicationsource code and/or execution events, to a user 725. For example,presentation interface 720 may include a display adapter (not shown)that may be coupled to a display device, such as a cathode ray tube(CRT), a liquid crystal display (LCD), an organic LED (OLED) display,and/or an “electronic ink” display. In some embodiments, presentationinterface 720 includes one or more display devices.

Computing device 622 further includes user input interface 735 thatenables user 725 to select a desired mode. When user 725 selects a mode,computing device 622 wirelessly transmits input signals to electricmotor 10 that cause electric motor 10 to operate in accordance with theselected mode.

User input interface 735 is coupled to processor 715 and receives inputfrom user 725. User input interface 735 may include, for example, akeyboard, a pointing device, a mouse, a stylus, a touch sensitive panel(e.g., a touch pad or a touch screen), a gyroscope, an accelerometer, aposition detector, and/or an audio user input interface. A singlecomponent, such as a touch screen, may function as both a display deviceof presentation interface 720 and user input interface 735.

In the exemplary embodiment, where electric motor 10 is implemented inan HVAC system, sensors 618 (shown in FIG. 6 ) detect an ambient airtemperature. In one embodiment, the detected air temperature iswirelessly transmitted to electric motor 10 via input signals. Motormanagement device 216 (shown in FIG. 3 ) receives the input signals andtransmits the input signals to computing device 622. Computing device622 may display the detected air temperature using presentationinterface 720. Presentation interface 720 may also display the currentlyselected mode.

Computing device 622 includes a communication interface 740 coupled toprocessor 715. Communication interface 740 communicates with one or moreelectric motors 10. In the exemplary embodiment, communication interface740 includes wireless communication unit 745, similar to wirelesscommunication module 508 (shown in FIG. 5 ), and a signal converter 750that converts the input signals received by wireless communication unit745. For example, in one embodiment, signal converter 750 converts ainput signal received by wireless communication unit 745 into a controlsignal that processor 715 utilizes to control operation of electricmotor 10. Computing device 622 may include more or fewer components thanthose specifically shown in FIG. 7 .

As compared to as least some known electric motor systems, the methodsand systems described herein utilize wireless sensor networks. Usingsensor connections, such as input signals in conjunction with wirelesstechnology such as Bluetooth® technology, and controlling electric motorsystem from a centralized system (e.g., a motor control assembly) inplace of several systems (e.g., a motor control assembly and externalsystem controllers) facilitates reducing costs associated withimplementing, maintaining, and operating electric motor systems. Forexample, a centralized system occupies less physical space as there isno need for additional hardware, and using input signal in conjunctionwith wireless communication such as Bluetooth® technology is generallyreliable. Furthermore, as compared to at least some known electric motorsystems, the systems and methods described herein enable configuring,controlling, and/or gathering data from a plurality of electric motorsin a relatively short time period, and in some embodiments,simultaneously.

The systems and methods described herein facilitate efficient andeconomical implementation, maintenance, and operation of an electricmotor system. Exemplary embodiments of methods and systems are describedand/or illustrated herein in detail. The methods and systems are notlimited to the specific embodiments described herein, but rather,components of each system, as well as steps of each method, may beutilized independently and separately from other components and stepsdescribed herein. Each component, and each method step, can also be usedin combination with other components and/or method steps.

When introducing elements/components/etc. of the methods and systemsdescribed and/or illustrated herein, the articles “a”, “an”, “the”, and“said” are intended to mean that there are one or more of theelement(s)/component(s)/etc. The terms “comprising”, “including”, and“having” are intended to be inclusive and mean that there may beadditional element(s)/component(s)/etc. other than the listedelement(s)/component(s)/etc.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

What is claimed is:
 1. An electric motor communication system using atleast one wireless sensor network, the electric motor communicationsystem comprising: at least one external transceiver device; a pluralityof electric motors communicatively coupled to the at least one wirelesssensor network, an electric motor of the plurality of electric motorscomprising: an electronics enclosure defining an internal chamberincluding a heat sharing chamber and a heatsink; a processing devicecoupled to the electric motor and configured to control operation of theelectric motor; and at least one sensor, of the at least one wirelesssensor network and in communication with the at least one externaltransceiver device, disposed within the heat sharing chamber of theelectronics enclosure of the electric motor, wherein the at least onesensor is configured to: measure at least one operating parameterassociated with the operation of the electric motor; transmit, fromwithin the electronics enclosure and to the processing device, at leastone input signal, wherein the processing device, in response toreceiving the at least one input signal, is configured to adjust theoperation of the electric motor; and transmit, from within theelectronics enclosure and to the at least one external transceiverdevice while maintaining communication with the electric motor, the atleast one input signal, wherein the at least one external transceiverdevice is configured to control a second operation of a second electricmotor of the plurality of electric motors by transmitting a controlcommand to the second electric motor based upon the at least one inputsignal.
 2. The electric motor communication system of claim 1, whereinthe at least one external transceiver device is a computing deviceincluding a plurality of user-selectable modes, wherein the at least oneexternal transceiver device is further configured to transmit thecontrol command to the electric motor that causes the electric motor tooperate in accordance with a selected mode of the plurality ofuser-selectable modes.
 3. The electric motor communication system ofclaim 1, wherein the at least one external transceiver device is adiagnostic tool configured to wirelessly collect diagnostic informationfrom the electric motor of the plurality of electric motors.
 4. Theelectric motor communication system of claim 1, wherein the at least oneexternal transceiver device is a sensing device configured to wirelesslytransmit sensor measurements to the electric motor.
 5. The electricmotor communication system of claim 4, wherein the sensing devicecomprises at least one of a CO/NOx sensor, a CO2 sensor, a vibrationsensor, a temperature sensor, a pressure transducer, an indoor airquality (IAQ) sensor, air flow sensor, radon sensor, and a second sensorthat measures a second operating parameter of the electric motor.
 6. Theelectric motor communication system of claim 1, wherein the at least oneexternal transceiver device is a database server configured towirelessly receive and store information transmitted from the at leastone sensor of the electric motor.
 7. The electric motor communicationsystem of claim 1, wherein the at least one input signal comprises awireless signal including at least one of a Wi-Fi, Z-Wave, a Bluetooth,and a Bluetooth Low Energy signal.
 8. The electric motor communicationsystem of claim 1, wherein the at least one external transceiver deviceis a sensing device associated with the second electric motor.
 9. Anelectric motor in communication with a wireless sensor network, theelectric motor comprising: an electronics enclosure defining an internalchamber including a heat sharing chamber and a heatsink; a processingdevice coupled to the electric motor and configured to control operationof the electric motor; and at least one sensor, of the wireless sensornetwork and in communication with at least one external transceiverdevice via the wireless sensor network, disposed within the heat sharingchamber of the electronics enclosure of the electric motor, wherein theat least one sensor is configured to: measure at least one operatingparameter associated with the operation of the electric motor; transmit,from within the electronics enclosure and to the processing device, atleast one input signal, wherein the processing device, in response toreceiving the at least one input signal, is configured to adjust theoperation of the electric motor; and transmit, from within theelectronics enclosure and to the at least one external transceiverdevice while maintaining communication with the electric motor, the atleast one input signal, wherein the at least one external transceiverdevice is configured to control a second operation of a second electricmotor by transmitting a control command to the second electric motorbased upon the at least one input signal.
 10. The electric motor ofclaim 9, wherein the at least one external transceiver device is acomputing device including a plurality of user-selectable modes, whereinthe at least one external transceiver device is further configured totransmit the control command to the electric motor that causes theelectric motor to operate in accordance with a selected mode of theplurality of user-selectable modes.
 11. The electric motor of claim 9,wherein the at least one external transceiver device is a diagnostictool configured to wirelessly collect diagnostic information from theelectric motor.
 12. The electric motor of claim 9, wherein the at leastone external transceiver device is a sensing device configured towirelessly transmit sensor measurements to the electric motor, andwherein the sensing device comprises at least one of a CO/NOx sensor, aCO2 sensor, a vibration sensor, a temperature sensor, a pressuretransducer, an indoor air quality (IAQ) sensor, air flow sensor, radonsensor, and a second sensor that measures a second operating parameterof the electric motor.
 13. The electric motor of claim 9, wherein the atleast one external transceiver device is a database server configured towirelessly receive and store information transmitted from the at leastone sensor of the electric motor.
 14. The electric motor of claim 9,wherein the at least one input signal comprises a wireless signalincluding at least one of a Wi-Fi, Z-Wave, a Bluetooth, and a BluetoothLow Energy signal.
 15. The electric motor of claim 9, wherein the atleast one external transceiver device is a sensing device associatedwith the second electric motor.
 16. A method of operating an electricmotor in communication with a wireless sensor network, the electricmotor including an electronics enclosure defining an internal chamberincluding a heat sharing chamber and a heatsink, a processing devicecoupled to the electric motor and configured to control operation of theelectric motor, and at least one sensor, of the wireless sensor network,disposed within the electronics enclosure of the electric motor and incommunication with at least one external transceiver device via thewireless sensor network, the method comprising: measuring, by the atleast one sensor, at least one operating parameter associated with theoperation of the electric motor; transmitting, from the at least onesensor within the electronics enclosure to the processing device, atleast one input signal, wherein the processing device, in response toreceiving the at least one input signal, is configured to adjust theoperation of the electric motor; and transmitting, from within theelectronics enclosure and to the at least one external transceiverdevice while maintaining communication with the electric motor, the atleast one input signal, wherein the at least one external transceiverdevice is configured to control a second operation of a second electricmotor by transmitting a control command to the second electric motorbased upon the at least one input signal.
 17. The method of claim 16,wherein the at least one external transceiver device comprises a sensingdevice, the sensing device comprising at least one of a CO/NOx sensor, aCO2 sensor, a vibration sensor, a temperature sensor, a pressuretransducer, an indoor air quality (IAQ) sensor, air flow sensor, radonsensor, and a second sensor that measures a second operating parameterof the electric motor, the method further comprising: sensing, by thesensing device, at least one sensor measurement; and transmitting, bythe sensing device to the electric motor, the at least one sensormeasurement.
 18. The method of claim 16, wherein the at least oneexternal transceiver device is a sensing device associated with thesecond electric motor.